Coated cloth and other resin and fiber compositions



Aug. 25, 1953 1.. P. BIEFELD 2,650,184

cousn cum; AND 0mm RESIN AND FIBER couPosITIoNs Filed Jan. 25; 1947 INVENTOR. LAWHBNZZE 1? 315mm ZMVQMM AT TYS.

Patented Aug. 25, 1953 COATED CLOTH AND FIBER co Lawrence P. Biefeld,

OTHER RESIN AND MPOSI'IIONS Newark, Ohio,

assignor to Owens-Corning Fiberglas Corporation, a corporation of Delaware Application January 25, 1947, Serial No. 724,316

2 Claims.

This invention relates to textile fabrics of glass fibers treated with resinous materials in the production of composite products having improved properties and characteristics. It relates particularly to coated cloth, that is, cloth combined with continuous void-free films of resinous materials, but is concerned also with composite materials having greater rigidity and form-retaining properties, such as resinous sheet material capable of being molded to desired shape in the making of articles of thin wall section.

Heretoforein the combination of glass fibers with resinous materials to form coated cloth or other thin sheet material, the effort among fabricators has been directed toward the development of a greater bond between the glass fiber surfaces and the resinous materials. This has been influenced by the belief that the properties of the one can only be transmitted to the other through the medium of an intimate bond; that the exceptionally high strengths of the glass fibers are imparted to the plastic through'the bond associating the fiber surfaces with the adjacent resinous bodies. I have found that this is not desirable in some cases. The bond between the ordinarily rigid resinous materials and the glass fibers prevents the relative movement of the fibers under stress so that, fairly low extensibility and high modulus of elasticity, the fibers of the fabric are easily broken under tearing stresses applied to the coated fabric, and the resin coated or impregnated fabric also exhibits lower strength under impact This is unlike the wool, cotton, cellulose or resinous fibers that are used in organic textile fabrication.

I have found that if the glass fibers are held in combination with the the fibers individually to move relative to each other, the strength, especially the tear, impact and bursting strengths, whether thecomposite massis exposed to wet or dry conditions, are puncture resistance and fiexure endurance are similarly improved. The freedom of movement of the fibers enables the fibers to act as bundles in resisting stresses substantially as if they were uncoated, instead of being subjected one by one to stresses. Furthermore, the resinous materials being present as substantial films or coatings are able to impart formability, color, and film continuity to the product as if the products were formed of sheets of pure resin. Thus, the properties of the resulting product are made cumulative and far surpass those of any one of the ingredients that make up the final composition.

greatly increased. The

movement resulting from the lack of adhesion contact between the glass fiber surfaces.

keep the adhesion between the fiber surfaces and the resinous bodies at a minimum. This and the products so made form a principal object of this invention.

Another duce a new A further object is a fabric of glass fibers the attributes and the method for producing a and resins having many of properties of the fibers and.

which the resinous materials do not trate into the fiber bundles enabling relative movement of the individual filaments or fibers tubing 01 glass fibers Qther objects and tion will hereinafter Figure 1 is a longitudinal central sectional view of a fabric ofglass fibers in combination with a film of resinous material disposed on one side thereof;

Figure 2 is a view of the elements of Figure 1 showing the resin disposition after the application of heat and pressure;

Figure 3 is a longitudinal central sectional view of a fabric of glass fibers disposed between two -resinous films;

According to the present invention, there is provided a fabric of glass fibers in the form of a, woven sheet covered on at least one side, but

preferably on both, with films of resinous material to provide a coated fabric for use as tentings, awnings,-tarpaulins, and the like, or a sheet stock for the manufacture of small molded articles.

Textile fabrics of glass fibers which have been found suitable for the purpose described may be formed by various methods. One method consists of the haphazard arrangement of glass fibers in a layer or fabric in which position the fibers are interbonded by means of a small amount of resin. This type of fabric is often referred to as a mat. Or the fabric of glass fibers may be made by interweaving substantially continuous yarns or strands of glass fibers on standard looms. A fabric of this type may be woven with both the warp l0 and fill ll yarns composed of glass fibers to produce a fabric having exceptionally high strengths in both the longitudinal and transverse directions. Or, only the warp or fill yarns may be formed of glass fibers, while the other, for example, the fill yarns, are formed of organic fibers, such as silk, wool, hemp, cotton. or synthetic organic fibers as nylon (polyamide resin), rayon, vinyon (vinylcopolymer) and the like.

'I'he yarns or strands may be formed of a multiplicity of discontinuous fibers drafted into a sliver or yarn. They may also be formed by attenuating hundreds of streams of molten glass flowing from a glass melting receptacle. These attenuated streams are collected into a single v 4 between film layers does not take place until the resinous materials are pressed together between heated platens whereby the resins flow sufilciently to fuse together at spaced apart points through the fabric. Thus, the glass filaments and in some cases the strands or yarns themselves are free to shift relative toeach other and to the resinous material. The desirable properties of both the resinous material and the textile fabric are thus retained in the product. This same concept is embodied in the use of more fiuid resinous compounds or other methods of resinous compound application wherein the interstices between the glass yarns in the fabric are substantially impregnated, yet the resinous v material is not sufilciently fiuid or of a composi- "tion adapted freely to enter into the yarn or strand which may be twisted or plied with other strands to form a yarn. Ordinarily in the continuous process, a size or lubricant is applied to the filaments before they are brought together. The size may consist of starch or a mixture of starches, hydrogenated oils, or other binding agents and lubricating agents individually or in combination. Since it is preferable to use a woven textile formed of yarns consisting of continuous filaments, the description of this invention will be made in connection with fabrics of that type. These woven textile fabrics may be closely woven, but for the purposes desired, it is preferable to use, a loosely woven, open fabric.

which readily permits the small bodies of resin to flow through the interstices, and also to enable greater deformation in the post forming of the resinous coated fabric in the manner later described.

In one aspect of the invention, the glass fiber fabric is impregnated with a resinous material which, as applied, does not fiow sufficiently to fill all of the. interstices between the glass yarns or strands. when the resinous material is fully deposited, the resin films on the faces of the fabric are connected to each other by a certain amount of keying at spaced apart points through the fabric. In some instances, the necessary bond strand and completely coatthe individual filaments. The resinous material thereby completely surrounds the strand or yarn but does not penetrate deeply into the yarn and the filaments in the fiber bundle are still free to move relative to each other and effect the desired result.

It is manifest that the ability of the resinous material to adhere to the glass fiber surfaces is of little importance in this aspect of the invention. Yet, the strength properties are further improved if the adhesion between the applied resin and glass fiber is low. Preferably, it is desirable to have no adhesion at all except for the small amount of mechanical adhesion caused by the surface characteristics of the yarns. This is illustrated in Figure 6 of the drawings.

As illustrated in Figure 1, disposed on one face of the fibrous fabric F is a film I2 of resinous material which might consist of a thin manufactured sheet, or else the film may be deposited there from a solution, emulsion or dispersion of the resinous material in suitable solvents or diluents, as by spraying, brushing, roller coating or dipping. However, in the latter instance, in view of the fact that it is desirable to apply the-material as a viscous dope lacking suiiicient fiow even partially to impregnate the fabric and fill the interstices between the fibers, it is preferable that application be made by a knife or roller coating process of a high solids content resin compound or solution. Suitable coating and impregnating resins may also comprise a highly plasticized resinous material in which the resin is dispersed as fine particles in the plasticizer to form what is often referred to as a plastiso in which there are no volatile products or a slightly less plasticized resin may be dispersed in a nonsolvent diluent to form what is often referred to as organosols. These, like the ordinary resinous dopes, may be spread onto the fabric by the knife or roller coating processes and the like.

After the solvents or diluents have been driven from the applied coating, leaving as a residue a resinous film, or else, if a prefabricated resinous sheet is disposed on one side of the fibrous fabric, the subsequent application of heat and pressure, as by the disposition of the filmedcloth between the heated platens of a press or heated calender rolls, renders the resinous plastic 50 that they may fuse or fiow through the interstices of the cloth subsequently to form a thin film I3 covering the opposite face of the fibrous fabric, as illustrated in Figure 2. In this operation, if the surfaces of the platens are smooth, the surfaces of the resinous films are likewise finished to provide a high gloss, as in press polishing."

As used herein, the term resinous material, comprising the residual film or sheet with which 5 l the glass fiber cloth is combined, includes both completely impregnate or contact the individual the rigid and non-rigid thermoplastic and the glas fibers, but the resin films are Joined tothermosettingnatural and synthetic resins. Ingether at spaced apart points by resin islands cluded among the thermosetting resinous cointhrough the fiber cloth. pounds are the poly-condensation products of 5 The following examples are illustrative of the phenol, urea, melamine and other phenolicj or invention:

amine compounds with aldehydes, such as form- 1 aldehyde, paraldehyde, furfuraldehyde or the EXAMPLE 1 like; the polymerization products of divinyl ben- Coating composit n-advent solut n ime zene and other styrene derivatives and halogene 5 ated products, allyl alcohol and its derivatives, 5:3: Simia acrylic esters, and the polyesters formed by the parts methyl ethyl ketone concomitant condensation and polymerization of parts ethyl acetate polybasic alcohols and the polycarboxylic acids 20 parts toluene or the like, or copolymer of the latter copoly- 15 merizable monomers.

Suitable non-rigid thermoplastic organic resy be applied to the surfaces of the glass fiber ins include the polymerization products of the f ric y means of the usual spray, dip, brush,

following thermoplastic -m having side chains spread, roller or knife coating processes. One or of substantially long carbon length to comprise 20 more passes may be made to build up the desired a permanently flexible polymer even when r'eth c n ss of film but between each passage the acted to the full extent of linear growth, such as mated fabllc 1S Subjected o elevated temperapolybutene, polybutylene, n-butyl methacrylate, tures in the range of to efiect the repolyvlnyl butyral, cellulose acetate-butyrate and moval of the Solvents e ied films are ordi- I'he above solvent solution of the clear resins the like, low molecular weight polymers Insulin narily of dull appearance and frequently the 7 ing from the interruption of the polymerization resin Solution has not flowed su ly to t n reaction of the following thermoplastic resin trate into the interstices between the fabric forming monomers before the polymer has yams- 9 Purposes of imparting 8 glos y finish reached the full extent of linear growth, such as to the resinous filmsthe Sheets are p sed 8- polystyrene having an average molecular weight tween calender rolls or platens heated to 250- t it chlo hated, fc l rol fgg azigf gefii fi fi g 2 flow sufficiently to enter the interstices and fuse tate having molecular weight below 3,000,- or the wlthportwns of the lm fr m the opposite face. thermoplastic resinous materials reacted to the The surfaces also take 011 h Polished finish of full extent of linear growth such as the cellulose the engaging wall- This is known as s esters, including cellulose acetate, cellulose buty lshmgx rate or the like, cellulose ethers as ethyl cellulose, EXAMPLE 2 benzyl cellulose or nitro cellulose, polystyrene or Coating composition-Later: type chlorinated polystyrene, acrylic esters, vinyl acetate, vinyl alcohol, vinyl chloride, vinyl acetals, 40 parzs gf g i copolymers of vinyl acetate and vinyl chlorides. 39 parts '2 Y1 ph ha ate polyvinylidene chloride-vinyl chloride copolyg mers, polybutene, polyethylene, polychloroprene, 1 par lspersmg agent butadiene-acrylonitrile copolymers, and other T organic polymerization products. into a heavy aqueous dispersion and applied to When the latter resinous materials are unthe surface of the textile fabric of glass fibers by plasticized, a more rigid formable heet is proany of the methods described. The viscosity of vided having the attributes of a fabricated plasthis coating composition is such that the distic sheet and the improved properties as prepersion principally coats the surface of the fabviously pointed out. Also included is rubber or ric, but if the greater pressures are used in aprubber-like compounds both synthetic or natural plication, the material may be made to how into in solution, emulsion or dispersion or in sheet the interstices between the yarns but not sufil- I form. These include the butadiene-styrene ciently to coat the individual fibers. The water (buna S) rubbers, thickol, butadiene-acrylonitrile is driven off on exposure of the coated fabric to rubbers, neoprene and the like. elevated temperatures ranging from 250 to 300 F.

It is to be understood that the resinous mafor a shortperiod of time. The resins in the disterial may also include the more recently develpersion are deposited as fine particles which are oped organo-silicon compounds such the the conthen fused in place by means of heating to fusion densation products of the hydrolyzed silanes to temperatures of 300 to 400 F., or by press polishproduce heat hardenable and plasticizable polying the fabric between heated platen or calsiloxanes or silicones, such for example as the ender rolls.

flexible di-octyl-polysiloxane, the more rigid diethyl-polysiloxane, di-methyl-polysiloxane, or an EXAMPLE 3 benzyl silicone, or the rubber-like di-methyl sili- Coating c0mp0sition0rganosol type cone elastomer. In all of these compounds, the 28 parts vjnymemv 19 parts di-octyl phthalate through the carbon atom The radical may consist of the open-chain hydrocarbons such as 5:3: K 352 5 oxide the aliphatic or acyclic hydrocarbons with a hy- 13 parts petroleum naphtha drogen removed, or the closed chain or ring compounds such as the alicyclic, aromatic or hetero- 30 parts xylene cyclic compounds or their derivatives with a hy- The organosol is a viscous high solids condrogen removed; Although thesematerials ext t c mp und in wh ch th r sin us parti l s hibit good adhesion to glass, combinations can are ispersed in hinners which do not operate to be made in such a manner that the resins do not s lv th r s ns. The organoso1" composition 7 is applied to the textile fabric of glass fibers by any of the dip. spread, roller or knife coating processes. The coated fabric is first heated at 225 to 275'F. to drive off the diluents and then it is heated to 300 to 400 F. to fuse the resin particles in place to form a continuous resinous film 'on the surfaces of the fabric. Similarly, to

the latex, the organosol may be made to imfor relative movement. The coated fabric may be press polished to improve the sheen as well as to further harden the coating.

EXAMPLE 4 Coating eoanposition-Plastisol type 42 parts vinylite VYNW 32 parts di-octyl phthalate parts tri-cresyl phosphate 10 parts whiting 6 parts iron oxide The plastisol is a viscous 100 percent solids content compound in which the resinous material is dispersed as fine particles in the plasticlzer. The compound is handled and treated similarly to that described in connection with the organosols." Since no diluents are present to be driven oil, the coated fabric may be immediately heated to the resin fusion temperature.

The adhesion of the resinous coatings may be further reduced by employing a higher twist in the yarns of the interwoven fabric. For'instance increasing the twist of the yarns from about four and one-half turnsper inch to seven and onehalf turns per inch achieves improvements in fiexure endurance and tear strength of over 100 percent and of about seventy-five percent respectively in the coated fabric.

The adhesion of most resinous materials to the glass fiber surfaces is also further reduced and the wet strength of the resin and fiber combination increased if the glass fibers are first coated with cationic amine salts, including the 'quaternary ammonium salts, having a long chain alkyl group greater than 10 carbon atoms in the positive radical. The same result is also achieved by first applying to the fibers organo-silicon compounds such as the halogenated silanes and their hydrolyzed polycondensation products in which. in the silane, the organic radical is connected to the silicon atom through the carbon atom in accordance with the formula ReSiX4-n, where X is a halogen, n is a number from 1-3, and R is a saturated or unsaturated organic radical selected from the group of open chain aliphatic or acyclic hydrocarbons, closed chain or ring compounds such as the alicyclic, carbocyclic or heterocyclic hydrocarbons or their homologues or derivatives. Instead of either of these, there may be used the organo-metallic complexes such as cyanoacetic acid chrome complexes. Formulations illustrating suitable treating materials are as follows:

EXAMPLE '5 Glass finishing compound: organo-silicon resin 1 part octadecyl trlchloro silane 99 parts toluene The finish compound is applied to the glass fiber surfaces and dried at 150 to 250 F. For such glass surfaces may be first removed, as by pyrol-.

ysis or by means of an aqueous soda ash solution, but this is not necessary; The resin materials previously described may be. applied to the textile 5 formed or the treated glass fibers. The resinous materials which penetrate into the fabric do not operate effectively to bond the glass fibers in'place and they are able to move relative to each other and the resinous materials as desired.

EXAMPLE-6 Glassfiber finishing compound: oraanometallic salt 2 parts stearato chromic-chloride supplied under the designation of crust AI by the E. 1. DuPont Company 98 parts water This solution is applied to the surfaces of the glass fibers by the dip coating process and dried thereon at 200 to 300 F. The starch or other size applied to the fibers during their manufacture may be removed from the fiber surfaces by being burned or washed off before this treatment.

The treated fabric is adapted to be coated with the 'previously described resinous materials such, for example, as that of Example 3.

EXAM LE'I Glass fiber finishing compound: cationicamine salt 2 parts of the reaction product of acetic acid with tetra ethylene pentamine stearate 98 parts water The solution is applied by one of the ordinary coating processes and dried at 200 to 300 F. for several minutes. -The treated fabric is coated with resinous material such, for example, as the coating material of Example 4.

Not infrequently even greater reduction in may comprise various'resinous mixtures in dilute solution or other lubricant and treating materials, s'uch, for example, as other organo-metallic complexes or organo-silicon resins.

Some resinous mixtures and metallic complexes which have been effective in the reduction of adhesion between the resinous materials and the previously treated glass fibers are as follows:

EXAMPLE 8 1 Second fiber finishing compound 15 parts buna N synthetic rubber 10 parts vinyl chloride-acetate copolymer '75 parts carbitol 0 The treating material is applied by a dippin process onto a textile fabric having the fibers previously treated with the compound described in Example 6. The treated fabric is dried at temperatures ranging from 250 to 400 F. and

then coated with the resinous materials set forth,

such, for example, as that described in Example 3. EXAMPLE 9 Second finishing compound 1 part cyano acetic acid 1-3 parts chromic chloride 98-96 parts water The textile fabric of glass fibers which have purposes, the first size previously applied to the been previously sized and treated with a com- Example 6, is coated with the above composition This treated fabric and dried at 200 to 300 F. is then coated with the resinous material which has less adhesion to the chromic-complex formed on the above composition.

These treating materials eflectively inhibit the complete wetting of the fibers by the coating compositions, so that ready flow of the coating compound, as by penetration into the yarn is eifectively resisted. The resin solutions, emulsions or dispersions, as a result, merely coat the outer wall of the yarn and not the fibers in the yarn bundle. The fibers are left free to move relative to each other. These treating materials also improve the wet strength of the composite mass so that a more desirable product results,

The product of this invention may be in the form of either fairly rigid sheet stock or pliable treated fabric depending upon the degree to which the resinous material is plasticized. The

product is produced in the form of a sandwich of two or more layers or films of resinous material l5 and is having between them a textile fabric of glass fibers H. The resin 24 may be applied from a solution or dispersion having sufficient to fill the interstices 25 between 26, as illustrated in Figure 6 of the drawings. Thus the glass fibers in the strand or yarn 2B are not bonded one to another and are free for relative movement. In this instance a subsequent heating and pressing operation may not be necessary to efiect the interlocking. But, if the resin and glass fibers are applied, as previously described and illustrated in Figure 3 of the drawings, they are combined between heated platens or rolls in a manner to render the resinous material plastic so that it may flow through the interstices of the cloth. Thus, the resinous films are joined together at spaced apart points I 6, but they do not completely coat the fibers to impair their movement or function. Where resin and fiber contact is made, the lack of adhesion enhances the ability of their movements relative to each other.

Pliable sheets of the type described are suitable as a textile fabric for tarpaulins, awnings, tentings, drapes, shower curtains, raincoats or the like, whereas the more rigid formable sheets may be molded into lamp shades, trays, window lights or the like, or laminated to form table tops, panels, or other structural or decorative items where exceptional tear and breaking strengths are desired.

Selectively, a resinous compound having an'index of refraction similar to that of the glass fiber compound might be used to produce substantially transparent sheets. In a similar manner, resin and resinous combinations may be formulated which will not support combustion so as to produce a non-inflammable treated textile fabric.

Included in the later group of resins are the vinyl chlorides and their copolymers with the vinyl acetates, vinylidene chloride, chlorinated styrene and the like. Suitable non-inflammable plasticizers adapted to be compounded with various resins to reduce their inflammability comprise the aromatic phosphates such as tricresylphosphate, chlorinated paramns or aromatics and the like.

One excellent fabrication of the type described is illustrated as a fiexible hose H in Figure 5 and comprises a glass fiber fabric in the form of a sleeve 20 sandwiched between outer and inner electrical insulation tapes,

10 layers 2| and 22 respectively of resinous material of the types described. n

to join the resin films comprising: a composite structure suitable for many purposes and-able to withstand considerable pressures tending to burst the tub ng.

Resinous materials, as previously described, are suitable for this purpose, including such formulations, for example, as set forth in Examples 1 to ,4. These compositions may be applied to the sleeving by the dip-squeeze method, the resinous solids content such as the "plastisols of Example 4, the "organosols trated by Example 3, or hot melts illustrated by 511118 1liiliighly plasticized ethyl cellulose materials or to each other.

pended claims.

I claim: 1. The method of making a sheet of the type described, consisting of a resinophobic composition that lubricates the fibers, and reduces the wetting out and adhesion of resinous materials to the fiber surfaces and selected from the group of Werner complex compounds having an organic acido group coordinated with the trivalent nuclear chromium atom, organosilicon compounds and cationic amine salts, coating the textile fabric with a viscous 11 resinous composition whereby the resin flows through some of the interstices-between strands of the fabric, but does not enter the strands to any appreciable extent so that the glass fibers remain substantially free of the resin to permit relative movement, and then treating the coated 4 fabric to harden the resinous materials.

2. The method of makin a sheet of the type described consisting of forming a textile fabric of strands of glass fibers, coating the fibers with a resinophobic composition having lubricating characteristics to reduce the wetting out and adlocked one with the other, and then treatins the' coated fabric to harden the resinous material.

LAWRENCE P. BIEFEID.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date Baird et a1. Oct. 11. 1938 Thomas Dec. 26, 1939 Hyatt et al June 18, 1940 Shand et al July 30, 1940 Powers Dec. 10, 1940 Owens June 3, 1941 Strauss --May 5, 1942 Ford et al July 18, 1944 Parker Aug. 28, 1945 Collins July 30, 1946 Rheinfrank Jan. 14, 194'I Delmonte Apr. 22, 1947 

2. THE METHOD OF MAKING A SHEET OF THE TYPE DESCRIBED CONSISTING OF FORMING A TEXTILE FABRIC OF STRANDS OF GLASS FIBERS, COATING THE FIBERS WITH A RESINOPHOBIC COMPOSITION HAVING LUBRICATING CHARACTERISTICS TO REDUCE THE WETTING OUT AND ADHESION OF RESINOUS MATERIALS TO THE GLASS FIBER SURFACES, COATING THE TEXTILE FABRIC WITH A PLIABLE FILM OF A RESINOUS MATERIAL WHICH BECAUSE OF THE RESINOPHOBIC CHARACTERISTICS OF THE GLASS FIBER SURFACES IS INCAPABLE OF SUBSTANTIAL PENETRATION INTO THE STRANDS TO BIND THE GLASS FIBERS BUT IS CAPABLE OF PENETRATION THROUGH THE INTERSTICES BETWEEN THE STRANDS IN THE FABRIC TO FORM RESINOUS ISLANDS BY WHICH THE COATINGS ARE INTERLOCKED ONE WITH THE OTHER, AND THEN TREATING THE COATED FABRIC TO HARDEN THE RESINOUS MATERIAL. 